Bituminous construction material and process of making the same



R. P. PERRY.

BITUMINOUS CONSTRUCTION MATERIAL AND PROCESS 0F MAKING THE SAME.

APPLICATION FILED APII.26, IQII.

1,409,767. mma Mar. 1.4, 1922.

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BITUMINOUS CONSTRUCTION MATERIAL D PROCESS OF MAKING THE SAM.

maaier.

Specification of Letters Patent.

Patented Mar. 14,1922.

Application filedV April 2G, 1917, Serial No. 164,663'.

T 0 @ZZ whom it may oon/cern.'

Be it known that I, RAY P, PERRY, a citizen or' the' United States,residing at 22 Parkside, 'Upper Montclair, in the county of Essex andState ot' New Jersey, have invented certain new and yuset'ulImprovements in Bituminous Construct-ion Materials and Processes ofMaking the Same, of which the following is a specification.

Thislinvention relates to rooting or construction materials ot abituminous or analogous character. Such lmaterials are generally made ota base ot so-called dry roofing telt, saturated with a waterprooiingcompound such as bituminous material, as asphalt, tor example, andusually areV coated with a waterproofing substance generally of abituminous character, as pitch or asphalt.

IVhatever the exact nature and construction ot the bituminous oranalogous material may be, it is the object ot my invention to provideeither both or but one of thesides of such rooting or constructionmaterial, generally the weather side, with a surface ot such a characterthat the construci tion material has `superior wearing qualities and theouter layer ot bituminous material, as the coating on the saturatedfelt, for example, is strengthened and reinforced.

Another object ot' my invent-ion is to provide such a character ofsurface tor the roofing material that when the material is packed inlayers or is rolled in a series of convolutions to form a. roll, thesuccessive layers or. convolutions have a minimum likelihood 'ofsticking to one another. This sticking together ot the` successivelayers or convolutions ot' the rooting material is iindesirableandhurmiul, Otten resulting in tearing away, or at least injuring anddei'aoing the Surface ot the successive layers or convolutions ot` ltheconstruction material.v Moreover, the character ot surtaceV provided lbyme for the rooting material is such that the rooting material may beapplied to the root. wall or other surface Where the same is to be laidwith the least possible injury to the more. or less Vfragile surface orsurface coating ot the same. Ordinarily the shoes of the workmenapplying the rooting material to the structure on whichfthe saine is tobe laid, Contact heavily with the surface of the rooting material, `tothe injury and damage of t-he same, especially from turning on the heelsor from slightly'projecting nails in the bottoms `Ot the shoes. By myconstruction I minimize such injuries without sacrificing any desirableproperties of my rooting material.

` I attain these desirable properties and others subsequently to beenumerated by providing` the rooting or construction material vofbituminous or analogous material with `a series of predetermined raisedribs or ridges integral with and made of the same material as thecoating of the construction material.

l-ly the terms Cribs and ridges I intend to indicate that portion of thecoating on the sheet proper which is at the points of maximum totalthickness ot the sheet, there being portions ot minimum thickness whichI designate by the term depressions Some i'orms of rooingor constructionmaterial are sometimes made With one or both surfaces thereotl coveredWith sand, crushed slate, grit, gravel, etc., and such sheets naturallyhave a small variation in thickness due to the varying size anddisposition of the irregular particles on the surface thereot'. In somecases I may provide rooting or construction material having suoli acovering (particularly where such covering consists ot relatively tineparticles, such as sand), with ribs or ridges, the irregular mineralsurfacing material being broken or otherwise.formed so as'to acquirethede# siredshape, Primarily, however, I treat sheets which are coveredwith finely powdered soap-stone, talc and analogous material, theparticles ot' Vwhich are relatively very tine and do not materiallyali'ect the thickness ot the sheet so 'tar as such dimension isre'lerred to herein.

' The exact disposition and dimensions ot the ribs or ridges aregenerally immaterial, and may be varied to suit different condi-A tions.Good results may be obtained by making the ribs or ridges ot a depthequal to less than t, generally 16 to -gof the minimum thickness ot' thesheet ot rooting material. It is'essential, in order thatl the betweenthe ridges be definitely predetermined. It is obvious that whenever ribsor lridges are located close together it is immaterial whether thesurface of the sheet be described by referring to the upstand-ing ribsorby referring to the corresponding depressions defined thereby. Thedepressions may, of course, be a set of parallel grooves, or sets ofintersecting grooves or may be merev pockets as outlined by the locationof the ribs or ridges which define and locate the same, and determinetheir disposition and dimensions. Such predetermination of the-.heightof the ribs or ridges and the depth ofl the pockets or depressions is ofconsiderable y importance as rendering certain the provision of anecessary minimum thickness of the weatherproofing` coating when such acoating is applied to a saturated or otherwise waterproofed sheet offelt or fabric. The total area occupied by the ridges on the surface` ofthe roofing material to which the ridges are applied may be andgenerally preferably is less than if, usually about to 3?; of the areaof the surface to which the ridges are applied, though such proportionsmay be variedas desired.

The essential point, however, is that the number, location anddimensions of the ribs, ridges or elevated portions, and also of thedepressedportions, are predetermined, instead of being indeterminate orrelatively haphazard, as in the case of the ordinary socalled rubberroofings of commerce, and especially such roongs as have the so-calledalligatorior rough surface, In accordance with my invention, when 'it isdesired' to reduce to a minimum the amount of material used in `the ribsor elevated portions, such ribs may be made in the form of narrow linesor ridges 0f predetermined small crosssection, and? the number of suchribs or ridges may be made relatively small. These ribs or ridges servealso to define or mark offy the lower or relatively depressed portionsof the sheet, which depressed portions are, as stated, also ofpredetermined dimensions and have a substantially definite minimumthickness so as to insure a definite wearing and weathering strength.

Referring tothe drawings wherein I have illustrated severalmodifications of my invention, Fig. l shows in plan view a portion ofone type of roofing material made in accordance with myinvent-ion. Fig.2 shows in cross-section the roofing material illustrated in Fig. 1.Fig. 8 shows in elevation and Fig. 4f in cross-section a furthermodification of my invention.

Fig. 5 shows in cross-section still another modification.

Fig. 6 shows an elevation and Fig. 7 a cross-section of a still furthermodification of my invention.

` Fig. 8 shows in elevation another modification of my invention.

Fig 9 shows in end elevation the roofing material illustrated in Figs. 1and 2 but rolled in convolutions to form a roll. for the purpose ofemphasizing one of the main advantages of my form of construction.

Fig. 10 shows an end elevation of a further modification of myinvention, and Fig. 11 shows in plan view still another modification.

Referring to the species of my invention illustrated in Figs. 1 and 2, Ais a strip of bituminous roofing material, having the usual coatings a,a of bituminous material, such as asphalt, pitch, etc., thereon. On theupper or weather surface of thek roofing material are the ribs B, Bdefining between them the pockets or depressions, C, C, C. In thespecies under discussion the ribs are substantially square orrectangular in crosssection and Substantially straight in longitudinaldimension. However, any desired form of cross-sectional character may beused with success for such ribs. Also, the ribs may be curved or mayotherwise be varied from the straight line form illust'rated. From aninspection of Fig. 2 it may be noted that kwhile the ribs are not veryhigh, forming but a small fraction of the entire depth of the roofingmaterial,` they form a considerable proportion of the maximum depth ofthe coating, where such coating is used, serving to vreinforce the same.Since the ribs are of comparatively small elevational area, by which Imean that the ribs occupy but a small portion of 105 the area of thesurface to lwhich they are applied, they reinforce the sheet andincrease the maximum thickness of the coating on the roofing material,without depriving the unribbed portions of the surface of 110 theroofing material to which the ribs are applied of more than a vsmallamount of coating material. `This point is of considerable practicalimportance as insuring that no part of the bituminous or equivalentcoat- 115 ingwill be unduly thinned and weakened to the injury andimpairment of the weathering properties of the roofing material.

It is immaterial for the purposes of my present invention just-how theribs are pro- 120 duced. It is, however, essential, for -the reasonsalready set forth, that the height of the ribs and the depth of thedepressions, as well as their number and location, be predetermined, soas not to provide ythin or 125 weak spots in the surface of the roofingmaterial. Generally the depressions are made by passing the sheet ofroofing material, coated with bituminous material, between rolls, eitheror both of which have appro- 130 priate v'markings 'on' them, accordingto whether one or both sides of the sheet of roofing material are to beprovided with ribs or ridges. The sheet to be 'provided with such ribsor ridges may be passed between the ribbing or ridging rolls after beingcoated or formed, while it is still in quite a plastic condition; oritmay vbe passed between such rolls when relatively cold, the bituminousmaterial even when cold being generally capable -of receiving andretaining the desired ribs or ridges. In any event the means and methodwhereby the ribs are formed areimmaterial so far as my present inventionis concerned.

f In Figs. 3 and 4,`wherein is illustrated another species Of-myinvention, the strip A1 of roofing material is shown provided with thecoatings al, al, of bituminous material. The strip is tapered like theordinary wooden shingle and is provided with two rows of ribs B1 andBgfat substantially right angles to each other, the intersecting ribsserving to define the pockets or depressions Cl, (Il. The ribs are shownas being triangular in cross-section but may be of' any other desiredcross-sectional character.

In Fig.l 5 I have illustrated a structure similar to that shown in Figs.3 and 4L wherein the tapered strip A is provided with the coatings a2,a2 and the intersecting ribs B3 defining pockets C3, except that in thiscase only the weather portion of the strip is provided with thereinforcing ribs or ridges, leaving the portion A3 unribbed.

If desired, as shown in Figs. 6 and 7 illustrating a furthermodification of my invention, the ribs may cover only a part or portionof the area of the strip to which the same are applied. In this caseboth sides of the strip AJI are provided with the coatings c3, a3 whichare inturn provided with staggered series of intersecting ribs B5 andBG, defining the depressions C, and leaving a seriesof unribbed portionsor areas E, E, E on both sides of the strip. The ribs B5 and 13 are hereshown as being semi-circular in cross-section.

As shown in Fig. 8, the strip A5 is provided with two series of ribs B6and B7 intersecting to form non rectangular pockets C5, the ribs beingshown as coating the longitudinal sides of the strip at angles otherthan right angles. If desired, the ribs may cross each other and thesides of the strip at any desired angles, and may be curved in anydesired way or be straight as desired.

IVhile the area covered by the ribs or ridges may be and generally isless rthan the total area of the depressed portions. the reverse may betrue. Such an arrangement is shown in Fig. 10 where the strip Ab.,having the coatings a4, a4, is provided on one of its faces with theribs B8, defining the depressions C. In this case the area covered bydepressions.

the ribs is greater than the total area of the In any case it is to benoted that the essential feature in each of the modifications is thatthe dimensions of the ribs or ridges and of the depressions, also theirnumber and disposition, be definitely predetermined for the reasonsalready set forth.- A

As shown in Fig. 11, the ribs may be curved, the strip A7 being providedwith various types of curved ribs asshown, one series of ribs B.J isannular, and defines the enclosed circular depressions C7; the ribs B10are contacting annuli, defining the enclosed circular depressions C8;while the ribs B11 are contacting annuli, each annulus being traversedby the connecting cross-shaped ribs B12, the combined arrangement` ofribs serving to define the depressions C, in the form of quartercircles.

By my construction the strip of roofing or construction material, andespecially the outer weather covering or coating of the same isstrengthened and reinforced without depriving the rest of the surfacecovering of any undue amount of coating material. By

my mode of procedure I am enabled to regulate and predetermine theamount of material in the ribs and the depth vand thickness of the`depressed portions.

As previously stated, roofing materials prepared in accordance with myinvention may be applied to the roof or other part of the structure onwhich the same is to be usedy with less damage and injury to the surfaceof the same caused by the workmen treading upon the same. i

Similarly when the construction material made in accordance with myinvention is packed in layers or rolled in convolutions to form a roll,there is less danger of the successive layers or convolutions stickingt0- gether, since such layers or convolutions will be in contact at'only restricted portions, and not as formerly at all points of theoverlapping areas. This point is clearly brought outin Fig. 9 in thecase of a roll of construction material made like the materialillustrated in Figs. l and 2.

It is often found desirable, especially where the ribs or ridges areformed while` the strip is still hot and the bituminous or analogousmaterial is quite soft, in order to prevent the strip from sticking tothe ribbing rolls and to other strips shortly after its production, andwhile the surface of the bituminous coating is still quite plastic, toprovide additional means, such as a fine powder of talc or soapstoneapplied to the surface. and also, if desired, just previous to ribbingor ridging, in order to prevent the strip from sticking to the ribbingrolls or to' each other immediately after ribbing and before thebituminous material is cooled and hardened. In the case of the roofingmatelrial of lmy invention the depressions serve the added function ofproviding reservoirs or pockets for holding a substantiallypredetermined amount or supply of suc-h antisticking material, such lassoapstone, talc, etc., as shown at s in Fig. 9.

VVhileV the absolute size and dimensions of the ribs and depressions aregenerally imma terial, l generally space the ribs a fraction kof an inchapart, so that, in the case of ribs intersecting at right angles, forexample, .the said ribs may be spaced one-eighth of an inch apart, moreor less, as desired, so that in such a case, there are about Gtdepressions toV thefsquare inch. However, these figures are cited merelyby Way of example, as indicating that the ribs or ridges and thedepressions delined'thereby may be, and generally are, quite small,though their absolute size is generally immaterial and may be va riedWithin :Wide limits.

Having described my invention, What l claim is: v

l. As anarticle of manufacture, a sheet of roofing material having abase coated With a layer of Waterproong material, said layer havingridges of predetermined cross-secl tional area thereon integral Withsaid layer,

said ridges being spaced less than l. apart.

2. As an article of manufacture, 'a sheet of roofing material having abase coated with a layer of Waterproofing material, said layer havingridges of predetermined cross-sectional area thereon integral with saidlayer, said ridges being spaced less than l apart and covering less thanof the total area of said layer.

3. As an article of manufacture, a sheet of roofing material coated withWaterproofing material, lia-ving on at least one side thereof aplurality of intersecting ribs of predeter` mined cross-sectional'areaintegral with the coating on which the ribs are located, Whereby aplurality of pockets of predetermined dimensions are formed, said ribsbeing spaced less than l apart.

4. As an article of manufacture, a sheet of roong'material coated 1vitha layer of Waterproofing material, said layer having a plurality ofintegral, parallel ridges spaced substantially equally and apredetermined distance less'than l apart, and of predeterminedcross-sectional area, and a similar series of ridges transverse to andintersecting the first series, whereby a series of uniform pockets ofpredetermined dimensions are produced on the sheet.

5. As an article of manufacture, a sheet of roofing material coated onat least'one side with Waterproofing material, said coat'- ing beingprovidedfvvith aplurality of predetermined, depressed portions spacedless than l apart for anti-sticking material.

6. As an article of manufacture, a coated sheet of roofing material ofsubstantially uniform thickness throughout its entire eX` tent, saidcoating having thereon a plurality of predetermined depressions Whosecenters mined dimensions spaced less than l apart,

all of the edges of said 'portions having substantially the same depth.

9. A sheet 0f bituminous coated composi tion roofing on Which at leastone side has a pattern in said coating comprising predetermined, raisedand depressed areas, the lines bounding the individual areas being notmore than l apart.

l0. Asheet of rooting material comprising a foundation sheet coated onat least one side with Waterproofing material, the exposed surfacecoating of which has raised and depressed portions predetermined as tosize and location, said raised portions being less than l apart.

1l. A sheet of roofing material comprising a foundation sheet coated onat least vone side with Waterproofing material, the eX- posed surfacecoating of Which has regularly disposed ribs thereon Whose centers aresubstantially JS apart.

In testimony whereof l aiiix my signature.

RAY P. PER-RY.

